Vent system for use with flooring systems

ABSTRACT

A vent system comprises a floor covering member for use as a finished floor and a metal member. The floor covering member comprises a plurality of first openings and has a first thickness that has been reduced by a first amount and the metal member is secured to a bottom surface of the reduced-thickness floor covering member. The metal member has a plurality of second openings aligned with the plurality of first openings.

FIELD

This disclosure is directed to a novel vent system and, in particular to a novel air vent cover.

BACKGROUND

Air vent covers are structures that cover a hole in a wall or floor at the area where an air duct enters an enclosed space, such as an interior room of a home. Conventional floor vents suffer from a number of deficiencies, including inferior strength, fit and finish, and aesthetics. Accordingly, it is desirable to provide a vent system for floors that provides improvements in structural strength, fit and finish, and general aesthetics.

SUMMARY

Various embodiments of a vent system, and methods of manufacturing and installing the vent systems are provided.

In one embodiment, a method of manufacturing a vent system for a finished floor comprises providing a floor covering member, reducing a thickness of the floor covering member by removing material from a bottom surface of the floor covering member, cutting the floor covering member to a predetermined width and a predetermined thickness, cutting a plurality of first vent openings in the floor covering member, providing a metal layer comprising a plurality of second vent openings, and adhering the metal layer to the bottom surface of the floor covering member with the plurality of first vent openings in alignment with the plurality of second vent openings to form a vent system. The floor covering member can be the same material as the finished floor to provide a refined and aesthetically-pleasing flooring system.

In other embodiments, a vent system is provided. The vent system comprises a floor covering member for use as a finished floor and a metal member. The floor covering member comprises a plurality of first openings and has a first thickness that has been reduced by a first amount and the metal member is secured to a bottom surface of the reduced-thickness floor covering member. The metal member has a plurality of second openings aligned with the plurality of first openings and a second thickness that is the same as the first amount.

In yet another embodiment, a method of installing a vent system in a finished floor is provided. The method includes providing a first opening in a subfloor, installing a plurality of floor covering members on the subfloor with a second opening that is aligned with the first opening and the second opening is larger than the first opening so that a portion of the subfloor that surrounds the first opening is exposed, positioning a vent system in the second opening so that it is supported by the exposed portion of the subfloor. The vent system comprises a metal member secured to a bottom surface of a reduced-thickness floor covering member.

The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vent system installed in an exemplary floor covering.

FIG. 2 is an exploded view of the vent system shown in FIG. 1.

FIG. 3 is a top view of a prepared recess in a floor covering that can receive a vent system.

FIG. 4 is a close-up view of an area from FIG. 2.

FIG. 5 is a schematic view of a portion of a floor covering installed on a subfloor.

FIG. 6 is a top view of an exemplary vent system.

FIG. 7 is a bottom view of the vent system shown in FIG. 6.

FIG. 8 is a side view of the vent system shown in FIG. 6.

FIG. 9 is another side view of the vent system shown in FIG. 6.

FIG. 10 is a cross-sectional view of an exemplary installed vent system.

DETAILED DESCRIPTION

General Considerations

As used in this application the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Furthermore, as used herein, the term “and/or” means any one item or combination of items in the phrase. In addition, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example,” introduce a list of one or more non-limiting embodiments, examples, instances, and/or illustrations.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, the description sometimes uses terms like “provide,” “produce,” “determine,” and “select” to describe the disclosed methods. These terms are high-level descriptions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art having the benefit of this disclosure.

The systems and methods described herein, and individual components thereof, should not be construed as being limited to the particular uses or systems described herein in any way. Instead, this disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and subcombinations with one another. For example, any features or aspects of the disclosed embodiments can be used in various combinations and subcombinations with one another, as will be recognized by an ordinarily skilled artisan in the relevant field(s) in view of the information disclosed herein. In addition, the disclosed systems, methods, and components thereof are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed things and methods require that any one or more specific advantages be present or problems be solved.

Exemplary Vent Systems

As used herein, the term “subfloor” refers to a sturdy structural base layer that provides a foundation for a finished “floor covering.” The subfloor may rest directly on joists or other support members. In some cases, the subfloor can comprise plywood, oriented strand-board (OSB), wood planks, or other suitable materials.

As used herein, the term “floor covering” refers to the visible surface or structure that is supported by the subfloor. The material of the floor covering is often selected to provide a more decorative or aesthetically pleasing appearance than the material that forms the subfloor. The floor covering can also be referred to, in some cases, as a “finish floor.” As used herein, the floor covering can include any material that has a finished surface, including, for example, solid wood flooring, engineered wood flooring, laminated flooring, luxury vinyl plank (LVP), and cork plank.

As used herein, the term “underlayment” refers to a material that can optionally be provided between the subfloor and the floor covering to provide one or more benefits, such as cushioning, sound absorption, and floor leveling. The underlayment can also function as a vapor barrier to prevent moisture from coming through and damaging the floor covering and/or as insulation to help regulate temperatures between the subfloor and floor covering. The underlayment is generally much thinner than the floor covering. In some cases, the underlayment can comprise polyethylene foam, felt, cork, or other suitable materials. The underlayment can be installed under the floor covering or, in some cases, it can be pre-attached to the bottom of the floor covering.

FIG. 1 illustrates a vent system 100 installed in a portion of a floor. In this regard, FIG. 1 shows a floor covering 102 on a surface of a subfloor 104. The subfloor 104 can be any suitable structural base layer that can support the floor covering 102. In one embodiment, for example, the subfloor 104 can include a plywood surface that supports the floor covering 102.

The floor covering 102 can be installed in any suitable manner. For example, plank floor coverings can be installed by cutting the planks to a desired size and snapping them in place on the subfloor using the tongue-and-groove structure of the planks (e.g., floating planks) or by otherwise adhering the planks to the floor with an adhesive material. Such installation methods are well-known.

As shown in FIG. 2, the vent system 100 need not be secured to the subfloor 104 so that it can be easily removed from a recess into which it rests. For example, the vent system 100 can be lifted out of the recess in which it rests. The recess can be formed by providing a first opening in the floor covering 102 that exposes a corresponding second opening in the subfloor 104 that is smaller than the first opening. The opening in the subfloor 104 can be a location where an air duct is positioned below the subfloor to supply conditioned air (e.g., heated or cooled air) into the area where the vent system is installed (e.g., a room of a home, business, or other space).

The floor cover opening (first opening) is preferably larger than the subfloor opening (second opening) in both a length and width direction. Thus, as shown in FIG. 3, floor covering opening width (FW) is larger than subfloor opening width (SW) and floor covering opening length (FL) is larger than subfloor opening length (SL). FIG. 10 also illustrates the subfloor opening (SO).

By providing a larger floor covering opening (first opening) than the subfloor opening (second opening) a portion of the subfloor 104 is exposed by the floor covering opening. This exposed portion of the subfloor 104 forms a support structure 106 onto which the vent system 100 can be positioned. As shown in FIGS. 2 and 3, the support structure 106 and adjacent walls of the floor covering opening 108, 110, 112, 114 form the recess into which the vent system 100 can be received.

In the embodiment shown in FIGS. 2 and 3, the support structure 106 forms a ledge that extends into the floor covering opening. The support structure 106 preferably surrounds the entire subfloor opening (i.e., is exposed along the perimeter of the floor covering opening), so that the support structure 106 can provide support to the vent system 100 along the entire outer perimeter of the vent system 100. A width of the support structure 106 can be the same on all sides of the floor covering opening, or it can vary. Preferably, the width of the support structure 106 is at least 0.375 inch or, more preferably, at least 0.5 inch. In some embodiments, the width can be between 0.375 and 1.0 inches, although it should be appreciated that other widths are possible depending on the specific application for which the vent system is installed.

To better illustrate the support structure 106 and recess formed by the support structure 106 and adjacent walls 108, 110, 112, 114, FIG. 4 shows a partial view of the area 4 shown in FIG. 2. The ledge has a width (W1) adjacent wall 108 and a width (W2) adjacent wall 110. As discussed above, W1 and W2 can be substantially the same or these widths can be different.

The vent systems described herein can be used with any finished floor material, including, for example, solid wood flooring, engineered wood flooring, laminated flooring, luxury vinyl plank (LVP), and cork plank. FIG. 5 illustrates a schematic cross-sectional view of an exemplary floor covering 102 that has a finished surface 116 that is on top of on one or more layers of other materials. For example, finished surface 116 can comprise a laminate layer of a material that provides the finished surface, such as a veneer of a hard wood (e.g., as used with engineered wood flooring) or a photographic applique/decor layer under one or more protective layer (e.g., as used with laminated flooring or LVP). A base layer 118 (e.g., structural layer) can be provided beneath the finished surface. The base layer can include, for example, structural plywood for use with engineered wood flooring, dense fiber board for use with laminate flooring, or any other suitable structural materials. In some cases, one or more backing layers 120 (e.g., underlayment) can also be provided below the base layer.

FIGS. 6-9 illustrate an exemplary structure of a vent system 100. As shown in FIGS. 1 and 6, the top layer 116 (and upper surface) of the vent system 100 is the same as the finished surface of the floor covering. The custom match of the vent system 100 to the floor covering 102 thus provides an aesthetic advantage by reducing the visibility of the vent system 100 with an installed floor. Referring to FIGS. 8 and 9, the vent system 100 also comprises a bottom layer 122 that is formed from a metal material that can span the subfloor opening and provide a strong, supportive structure that can carry a significant amount of weight without substantial displacement or bending across the span. Between the top layer 116 and bottom layer 122, an intermediate layer can include a portion of the base layer of the floor covering. In particular, as discussed in more detail below, a thickness of the base layer (and/or other backing layers) is reduced, relative to the original flooring thickness, to provide a flush-mounting vent system 100.

As shown in FIGS. 6 and 7, a plurality of vent openings 124 extend completely through the vent system 100. The vent openings 124 therefore extend through the floor covering 116 portion of the vent system (top portion) and the metal bottom layer 122.

FIG. 10 shows a cross-sectional view of an exemplary floor system (e.g., floor covering and subfloor) with an exemplary vent system 100 installed there. As shown in FIG. 10, the vent system comprises a reduced thickness (RT) floor covering with a metal bottom layer 122 that is the same thickness (MT) as the amount that the floor covering has been reduced in thickness from the original floor covering thickness (FT).

In one embodiment, the vent system 100 can be formed by selecting a floor covering member (e.g., one or more planks depending on the width of the desired vent system and the width of the individual floor covering members), and reducing the thickness of the floor covering member by the thickness of the desired metal bottom layer (MT). After cutting the desired vent openings in the reduced thickness member, the metal bottom layer can be secured to the bottom surface of the reduced thickness member with the openings in the reduced thickness member and the openings in the metal bottom layer aligned as desired. Additional details of an exemplary method of forming a vent system are provided in the example below.

Example 1

A method of manufacturing a vent system can comprise the following steps:

1. Select a floor covering member (e.g., one or more planks depending on size of the opening).

2. Remove a portion of the back of the floor covering member (e.g., by planing off an amount of material that generally corresponds to the thickness of the metal bottom layer of the vent system.

3. Apply an adhesive tape to the back of the planed floor covering member.

4. Cut planed floor covering member to size and cut vent openings (e.g., by fastening the planed floor covering member to a CNC machine, upside down in some embodiments, and cutting to desired size with openings).

5. Secure metal bottom layer to floor covering member with openings in the metal bottom layer and openings in the floor covering member aligned (e.g., by removing the protective layer from the adhesive tape and adhering the metal bottom layer to the adhesive material).

Additional finishing steps can be performed during and/or after the above steps. For example, the areas that have been cut can be filed and/or buffed to remove any imperfections or to otherwise improve the appearance and/or function of the pieces. In addition, paint can be applied to portions of the vent system, such as between slats where the floor covering member has been cut, to reduce visibility of those portions and improve the overall appearance of the vent system 100.

It should be understood that the metal bottom layer can be secured to the back of the reduced-thickness floor covering member by any suitable means. In some embodiments, an adhesive can be used to permanently fix the metal bottom layer to the floor covering member. However, other methods of attachment, though perhaps less desirable, can also be used, such as mechanical fasteners.

In some embodiments a frame can be provided that surrounds the vent system 100. For example, as shown in FIGS. 1 and 2, a frame 126 can be added to completely surround the vent system 100. If a frame 126 is used, the floor covering opening must be cut to accommodate the frame. The frame can be formed from the same materials as the floor covering. For example, in one embodiment, the frame can be formed by cutting one or more floor covering members (e.g., planks) to a size and shape that can accommodate the vent system. The floor covering members can be cut, for example, using a CNC machine, finished as needed (e.g., filed/buffed and painted on the inside and outside edges of the frame).

The vent systems described herein can be produced in a variety of sizes, including the following vent sizes (all in inches): 4×10, 4×12, 4×14, 6×10, 6×12, 6×16. In addition, vent systems can be provided in any desired custom size and shape. For example, in some embodiments, a width of the vent system can range from 3 inches to 10 inches and a length can range from 5 inches to 20 inches. For vent sizes that require more than one floor covering piece (i.e., two or more planks), the floor covering pieces can be coupled together before being prepared as described herein (e.g., creating vent openings, reducing a thickness, and securing a metal bottom layer).

The metal bottom layer can be formed from steel and can have a thickness that provides sufficient load-bearing strength across the span of the vent system. In one embodiment, the steel can have a thickness that is equal to or greater than 0.10 inch and equal to or less than 0.2 inch. In addition, in some embodiments, a ratio of the thickness of the metal bottom layer (MT) to a thickness of the vent system (VT) can range from 0.1 to 0.5, or more preferably the ratio can range from 0.2 to 0.3.

For example, in one embodiment, the metal bottom layer can comprise 11 gauge steel with a thickness of 0.125 inch (MT) and the total thickness (VT) can be 0.5 inch, and the ratio can be 0.25. Similarly, in another embodiment, 12 gauge steel can be used with a thickness (MT) of 0.11 and ratio of 0.22.

Referring again to FIGS. 6 and 7, the strength of the metal bottom layer can also advantageously allow for a greater amount of free air space through the openings. In some embodiments, the ratio of the collective area of the plurality of openings 124 to a total area of the vent system can range from 0.3 to 0.7 or, more preferably from 0.4 to 0.55, or more preferably between 0.45 and 0.50. For example, for a 4×10 vent system, the total area is 40 square inches. With twenty openings having a width (W) of 0.25 inch and a length (L) of 3.75 inches, the collective area of the openings (i.e., the free air space of the vent system) is 18.75 square inches, and the ratio of the collective area of the openings to the total area of the vent system is 0.47. Similarly, in another embodiment, a 4×12 vent duct size has a total area of 48 square inches, twenty-four openings, a collective opening area of 22.5 inches (0.25×3.75×24), and a ratio of 0.47.

In the above example, the openings have a width (W) of 0.25 inch and a length (L) of 3.75 inches; however, it should be understood that other widths and lengths are possible. For example, in some embodiments the width of the openings can vary from 0.2 to 0.3 inch.

The vent systems described herein provide a number of advantages over conventional systems. For example, as discussed above the complete vent system 100 (e.g., floor covering portion and metal bottom layer) can be completely removed from the recess in which it is received. This provides easy access to the duct work for cleaning or other maintenance. Similarly, the installation of the vent system is simple and requires no special tools.

The vent systems described herein also provide improved aesthetics as the vent system can be custom matched to the adjacent floor covering. In addition, modifying a floor covering member as described herein results in a flush-mounted vent system.

The vent systems can also provide improved airflow since the plurality of openings in the vent system can provide a greater ratio of free air space of the openings to the total area of the vent system. 

I claim:
 1. A method of manufacturing a vent system for a finished floor comprising: providing a floor covering member; reducing a thickness of the floor covering member by removing material from a bottom surface of the floor covering member; cutting the floor covering member to a predetermined width and a predetermined thickness; cutting a plurality of first vent openings in the floor covering member; providing a metal layer comprising a plurality of second vent openings; and adhering the metal layer to the bottom surface of the floor covering member with the plurality of first vent openings in alignment with the plurality of second vent openings to form a vent system, wherein the floor covering member is the same material as the finished floor.
 2. The method of claim 1, wherein the floor covering member is a solid wood flooring, an engineered wood flooring, a laminated flooring, a luxury vinyl plank (LVP), or a cork plank.
 3. The method of claim 1, wherein the metal layer comprises steel.
 4. The method of claim 3, wherein the metal layer has a thickness that ranges from 0.1 to 0.2 inches.
 5. The method of claim 1, wherein a ratio of a collective area of the plurality of first vent openings to a total area of the vent system ranges from 0.4 to 0.55.
 6. The method claim 1, wherein the metal layer is attached to the bottom surface of the floor covering member with an adhesive.
 7. The method of claim 1, wherein an amount of the reduced thickness of the floor covering member is the same as a thickness of the metal layer.
 8. A vent system comprising: a floor covering member for use as a finished floor, the floor covering member comprising a plurality of first openings and having a first thickness that has been reduced by a first amount; and a metal member secured to a bottom surface of the reduced-thickness floor covering member, the metal member having a plurality of second openings aligned with the plurality of first openings and a second thickness that is the same as the first amount.
 9. The vent system of claim 8, wherein the floor covering member is a solid wood flooring, an engineered wood flooring, a laminated flooring, a luxury vinyl plank (LVP), or a cork plank.
 10. The vent system of claim 8, wherein the metal member comprises steel.
 11. The vent system of claim 10, wherein the metal member has a thickness that ranges from 0.1 to 0.2 inches.
 12. The vent system of claim 10, wherein a ratio of a collective area of the plurality of first openings to a total area of the vent system ranges from 0.4 to 0.55.
 13. The vent system of claim 10, wherein the metal member is attached to the bottom surface of the floor covering member with an adhesive.
 14. The vent system of claim 10, wherein an amount of the reduced thickness of the floor covering member is the same as a thickness of the metal member.
 15. A method of installing a vent system in a finished floor comprising: providing a first opening in a subfloor; installing a plurality of floor covering members on the subfloor with a second opening that is aligned with the first opening, the second opening being larger than the first opening so that a portion of the subfloor that surrounds the first opening is exposed; positioning a vent system in the second opening so that it is supported by the exposed portion of the subfloor, wherein the vent system comprises: at least one floor covering member, the at least one floor covering member including a plurality of first openings and having a first thickness that has been reduced by a first amount; and a metal member secured to a bottom surface of the reduced-thickness floor covering member, the metal member having a plurality of second openings aligned with the plurality of first openings and a second thickness that is the same as the first amount.
 16. The method of claim 15, further comprising a frame member that completely surrounds the first opening the frame member defining the second opening.
 17. The method of claim 15, wherein the plurality of floor covering members are solid wood planks, engineered wood planks, laminated planks, luxury vinyl planks (LVPs), or cork planks.
 18. The method of claim 15, wherein the metal member comprises steel that has a thickness that ranges from 0.1 to 0.2 inches.
 19. The method of claim 18, wherein a ratio of a collective area of the plurality of first openings to a total area of the vent system ranges from 0.4 to 0.55.
 20. The method of claim 18, wherein the metal member is attached to the bottom surface of the floor covering member with an adhesive. 